Packing vessel for thin sheet materials

ABSTRACT

A container having cooperating lower and upper members that are adapted to fit together so as to form a plurality of cavities, the lower member having a plurality of concave bottom surfaces and an annular channel surrounding each concave bottom surface, the upper

United States Patent 91 Abe [ PACKING VESSEL FOR THIN SHEET MATERIALS [75] Inventor: Iwao Abe, Nodashi, Chibaken,

Japan [73] Assignee: Chisso Corporation, Osaka, Japan [22] Filed: Jan. 11,1971

[21] Appl. No.: 105,276

[30] Foreign Application Priority Data Jan. 1, 1970 Japan ..45/3225 [52] US. Cl. ..206/65 F, 206/46 ED, 220/97 C, 220/97 F [51] Int. Cl ..B65d 21/00, B65d 71/00 [58] Field of Search ..206/l R, 46 FR, 46 H, 62 R, 206/65 F, 65 K, 46 ED; 220/4 R, 23.83, 97 C, 97 R, 97 D, 97 F; 229/25 [5 6] References Cited UNITED STATES PATENTS 3,672,495 6/1972 Bauer et al ..206/65 F 1 March 6, 1973 3,119,492 Burket..... 206/62 R 3,469,686 9/1969 Gutsche .206/65 F 3,146,929 9/1964 Keim ..229/2.5 3,191,791 6/1965 Jackson ..206/65 F X 3,482,682 12/1969 Cronkhite ..206/65 F 3,552,548 [/1971 Wallestad ..206/l R Primary ExaminerJoseph R. Leclair Assistant Examiner-Steven E. Lipman Attorney-Fred C. Philpitt [57] ABSTRACT A container having cooperating lower and upper members that are adapted to fit together so as to form a plurality of cavities, the lower member having a plurality of concave bottom surfaces and an annular channel surrounding each concave bottom surface, the upper member having a plurality of convex surfaces and an annular channel disposed around the periphery of each such convex surface, the channel sections of the upper and lower members being constructed so that they will interfit in a nesting relationship 10 Claims, 3 Drawing Figures PACKING VESSEL FOR THIN SHEET MATERIALS BACKGROUND AND OBJECTS The present invention relates to a packing container for thin sheet materials whose surfaces should not be soiled nor injured, for example, semiconductor wafers having mirror-like polished surfaces, glass filters for optical instruments, or the like.

l-leretofore various containers have been used for shipping semiconductor wafers, such as bag-like containers made of paper, synthetic resin film, containers shaped from synthetic resins, provided with partitions and containing a material such as sponge laid on their bottom, etc. However, in any of these containers, since the articles to be packed are brought directly into con-' tact with the packing materials of the container, the chance of soiling or injury during the time of their being transported and handled has been very great.

An object of the present invention is to provide a shipping container for thin sheet materials whereby the abovementioned drawbacks are overcome and the soiling or injury of surfaces due to the contact of the surface of the materials to be shipped with the packing materials is minimized or eliminated.

Another object of the present invention is to provide a shipping vessel for thin sheet materials which is light, compact and easy to handle. Further objects and advantages will become apparent after reading the detailed description which hereinafter follows.

THE INVENTION BROADLY In order to attain the abovementioned objects, I have found that the item to be packed, in whatever state it may be, should come into contact with the packing material over as small an area as possible, and preferably only at the marginal portions of the item to be shipped.

Considered from one aspect, my invention involves a container for thin sheet materials, such as semiconductor wafers, which comprises cooperating lower and upper members that are adapted to fit together so as to form a plurality of cavities, wherein:

A. said lower member is characterized by a. a plurality of spaced apart downwardly concave bottom surfaces,

b. a first annular channel section of a generally U- shaped configuration disposed around the periphery of each concave bottom surface,

B. said upper member is characterized by a. a plurality of spaced apart upwardly convex cover surfaces,

b. a second annular channel section disposed around the periphery of each convex cover surface which can be considered as consisting of a stepped U-shaped configuration that consists of a receptor portion and a projector portion that is smaller than said receptor portion,

C. said concave bottom surfaces and said convex cover surfaces being vertically aligned with each other when said lower and upper members are functioning as a container,

D. the exterior surface of said first annular channel section having a size and configuration that is adapted to fit within the interior surface of the receptor portion of said second annular channel section in a nesting relationship, and

E. the interior surface of said first annular channel section having a size and configuration that is adapted to accommodate the exterior surface of the projector portion of said second annular channel section in a nesting relationship.

THE DRAWINGS FIG. 1 shows cross-sectional views of upper and lower members according to a preferred embodiment of this invention;

FIG. 2 is a cross-sectional view showing how the lower members and upper members in accordance with this invention can be stacked together in a nesting relationship; and

FIG. 3 is a perspective view showing upper and lower members in accordance with this invention in a spaced apart relationship.

DETAILED DESCRIPTION Referring now to the drawings, the lower member 1 is shown as being positioned below an upper member 1. The lower member 1 has a concave bottom surface 4' which is surrounded by an annular channel section 2' of generally U-shaped configuration. More particularly, the annular channel section 2 consists of an annular inner side wall 5 extending upwardly from the periphery of said concave bottom surface 4', a bottom shelf portion 3' extending substantially horizontally outwardly from said sidewall 5' and an outer sidewall portion 8' extending substantially vertically downwardly from the outer periphery of said bottom shelf portion 3'.

The upper member 1 comprises an upwardly convex cover surface 4 that is surrounded by an annular channel section 2-12 and which can be considered as having a stepped U-shaped configuration that consists of a lower receptor portion 2 and an upper projector portion 12 that is smaller than said receptor portion. More particularly this annular channel section 2-12 comprises a first cover side wall portion 5 extending vertically upwardly from the periphery of said convex surface 4, a first cover shelf portion 1 1 extending substantially horizontally outwardly from said first cover sidewall portion 5, a second cover sidewall portion 9 extending vertically upwardly from the periphery of said first cover shelf portion 11, a second cover shelf portion 3 extending substantially horizontally outwardly from said second cover sidewall portion 9, a third cover sidewall portion 10 extending downwardly from the periphery of said second cover shelf portion 3, a third shelf portion 14, extending outwardly from the bottom of sidewall portion 10 and in the same plane as shelf portion 11, and a fourth sidewall portion 8 extending vertically downwardly from the periphery of said third shelf portion 14.

As can perhaps best be seen in FIG. 2, the exterior surface 7' of said first annular channel section 2' has a size and configuration that adapts it to fit within'the interior surface of the receptor portion 2 of the annular channel section 2-12 in a nesting relationship. Also, the interior surface of said first annular channel section 2 has a size and configuration that is adapted to accommodate the exterior surface 7 of the projector portion 12 of said second annular channel section 2-12 in a nesting relationship. This construction permits a plurality of container units to be stacked one upon the other in the manner shown in FIG. 2.

When an item made of thin sheet material to be packed is placed on one of my packing units or containers, it is loosely held between the downwardly concave and the upwardly convex surfaces 4' and 4, and only the marginal portions of the item come into contact with the container, regardless of the position of the packing unit or container. Thus, most of the surfaces of the item can be completely protected from staining or injury.

As for the configuration of the surfaces 4 and 4, any form will do so long as the flat surfaces of the item to be placed therein will have minimum contact with the surfaces 4 and 4'. However, the concave surfaces 4 and the convex surfaces 4 are preferably generally spherical in configuration, and are vertically aligned so that they are complementary with each other to thereby form cavities for the items to be shipped.

The spherically curved bottoms 4' may be provided with radial grooves 13 to facilitate removal of the item contained therein by a pincette (not shown).

Also, whereas the channel sections are shown as being generally U-shaped in configuration no invention would be involved in making them V-shaped, semi-circular, etc.

The packing unit or container of this invention is preferably shaped by vacuum forming from a sheet of synthetic resin material having a thickness within the range of about 0.1 mm to 1.0 mm and most preferably within the range of about 0.1 mm to 0.5mm. Suitable synthetic resins which may be used and which are suitable for forming by vacuum methods would include polyethylene, polypropylene, polystyrene, polyvinylchloride, or the like.

The packing unit or container of my invention requires no expensive mold (such as an injection mold) and can be simply shaped by vacuum forming to lower both the production cost and the cost of materials. Furthermore, the container of the present invention is convenient due to its light weight, and moreover, since a plurality of the containers can be stacked upon each other, a great advantage is gained in the transportation and space taken up by the product.

In conclusion, while there has been illustrated and described a preferred embodiment of my invention, it is to be understood that since the various details of construction may obviously be varied considerably without really departing from the basic principles and teachings of this invention, 1 do not limit myself to the precise constructions herein disclosed and the right is specifically reserved to encompass all changes and modifications coming withinthe scope of the invention as defined in the appended claims.

Having thus described my invention, what I claim as new and desire to secure a United States Letters Patent is:

l. A packing unit for thin sheet materials such as semiconductor wafers which comprises cooperating lower and upper members that are adapted to fit together so as to form at least one cavity,

A. said lower member being characterized by:

a. at least one downwardly concave bottom surface that forms the lower portion of said at least one cavity,

b. a substantially vertical annular inner sidewall extending upwardly from the periphery of each said concave bottom surface,

c. a bottom shelf portion extending substantially horizontally outwardly from said inner sidewall,

d. an outer sidewall portion extending substantially vertically downwardly from the outer periphery of said bottom shelf portion,

e. said bottom shelf portion and said outer sidewall defining an annular channel around the periphery of each concave bottom surface,

B. said upper member being characterized by a. at least one upwardly convex surface that forms the upper portion of said at least one cavity,

b. a first cover sidewall portion extending vertically upwardly from the periphery of each said convex surface,

c. a first cover shelf portion extending substantially horizontally outwardly from said first cover sidewall portion,

(1. the first cover sidewall portion and said first cover shelf portion being snugly interengageable with the outer surface of the corner formed by the said inner sidewall and the said bottom shelf portion of said lower member,

e. a second cover sidewall portion extending vertically upwardly from the periphery of said first cover shelf portion,

f. a second cover shelf portion extending substantially horizontally outwardly from said second cover sidewall portion,

. the aforesaid second cover sidewall portion and said second cover shelf portion having an outer surface configuration that is slightly smaller than the interior configuration of the corner formed by said inner sidewall and said bottom shelf portion of said lower member.

2. A packing unit according to claim 1 wherein said concave bottom surface is provided with a radial groove which is adapted to receive a pincette to facilitate the removal of the material resting on said surface.

3. A packing unit according to claim 1 wherein said packing unit is composed of a synthetic resin having a thickness between about 0.1 mm and about 1.0 mm.

4. A packing unit for items such as thin semiconductor wafers which comprises cooperating lower and upper members that are adapted to fit together so as to form a plurality of cavities:

A. said lower member being characterized by:

a. a plurality of spaced apart downwardly concave bottom surfaces that define the bottom portions of the aforesaid plurality of cavities,

b. a substantially vertical annular inner sidewall extending upwardly from the periphery of each of said concave bottom surfaces,

c. a bottom shelf portion extending substantially horizontally outwardly from the inner sidewall of each of said concave bottom surfaces,

d. outer sidewall portions extending substantially vertically downwardly from the outer periphery of each of said bottom shelf portions,

e. each of said bottom shelf portions of each of said outer sidewall portions defining an annularchannel around the periphery of each concave bottom surface,

B. said upper member being characterized by: together so as to form a plurality of cavities wherein:

a. a plurality of spaced apart upwardly convex sur- A. said lower member is characterized by faces that form the cover portions of said plua. a plurality of spaced apart downwardly concave rality of cavities, bottom surfaces,

b. a first cover sidewall portion t din v ti- 5 b. a first annular channel section of a generally U- cally upwardly from the periphery of each said shaped configuration disposed around the convex surface, periphery of each concave bottom surface,

c. a first cover shelf portion extending substantially Said PP member is characterized y horizontally outwardly from each said first cover a plurality of Spaced apart p y convex id ll i 10 cover surfaces, I

d. the under surface of the first cover sidewall pora second anPular Channel secnon dlsposed tion and the first cover shelf portion of each around P P p y each convex f f convex Surface being snugly interengageable face which can be considered as cons sting of a with the outer surface of the corner defined by Stepped P configurjmon that {names the intersection of said inner sidewall and said receptor porno and a prolector porno that smaller than said receptor portion,

C. said concave bottom surfaces and said convex cover surfaces being vertically aligned with each other when said lower and upper members are functioning as a container,

D. the exterior surface of said first annular channel section having a size and configuration that is adapted to fit within the interior surface of the receptor portion of said second annular channel bottom shelf portion of each corresponding concave surface in the lower member,

e. a second cover sidewall portion extending vertically upwardly from the periphery of each of said first cover shelf portions,

f. a second cover shelf portion extending substantially horizontally outwardly from each second cover sidewall portion,

g. each of the aforesaid second cover sidewall porsection in a nesting relationshi tlons and Second cove Shelf portions having an E. the interior surface of said fll'st annular channel outer surface configuration that is slightly section having a size and configuration that is smaller than the interior surface configuration adapted to accommodate the exteriorsurface of of the corner formed by the intersection of said the projector portion of said second annular chaninner sidewall portion and the bottom shelf pornel section in a nesting relationship.

tion of said lower member. 8. A container according to claim 7 wherein said 5. A packing unit according to claim 4 wherein said concave bottom surface is provided with a radial concave bottom surface is provided with a radial groove which is adapted to receive a pincette to groove which is ada t d t r c iv a i n to facilitate the removal of the material resting on said facilitate the removal of the material resting on said surfaces rf 9. A container according to claim 7 wherein said 6. A packing unit according to claim 4 wherein said Packing unit is composed of a Synthetic resin having a ki i i composed f a Synthetic resin having a thickness between about 0.1 mm and about 1.0 mm. hi k between about ()1 mm and about 1 mm 10. A container according to claim 7 wherein there,

7. A container unit for thin sheet materials such as are ten spaced cavities formed by the said PP semiconductor wafers which comprises cooperating andlower memberslower and upper members that are adapted to fit 

1. A packing unit for thin sheet materials such as semiconductor wafers which comprises cooperating lower and upper members that are adapted to fit together so as to form at least one cavity, A. said lower member being characterized by: a. at least one downwardly concave bottom surface that forms the lower portion of said at least one cavity, b. a substantially vertical annular inner sidewall extending upwardly from the periphery of each said concave bottom surface, c. a bottom shelf portion extending substantially horizontally outwardly from said inner sidewall, d. an outer sidewall portion extending substantially vertically downwardly from the outer periphery of said bottom shelf portion, e. said bottom shelf portion and said outer sidewall defining an annular channel around the periphery of each concave bottom surface, B. said upper member being characterized by a. at least one upwardly convex surface that forms the upper portion of said at least one cavity, b. a first cover sidewall portion extending vertically upwardly from the periphery of each said convex surface, c. a first cover shelf portion extending substantially horizontally outwardly from said first cover sidewall portion, d. the first cover sidewall portion and said first cover shelf portion being snugly interengageable with the outer surface of the corner formed by the said inner sidewall and the said bottom shelf portion of said lower member, e. a second cover sidewall portion extending vertically upwardly from the periphery of saiD first cover shelf portion, f. a second cover shelf portion extending substantially horizontally outwardly from said second cover sidewall portion, g. the aforesaid second cover sidewall portion and said second cover shelf portion having an outer surface configuration that is slightly smaller than the interior configuration of the corner formed by said inner sidewall and said bottom shelf portion of said lower member.
 1. A packing unit for thin sheet materials such as semiconductor wafers which comprises cooperating lower and upper members that are adapted to fit together so as to form at least one cavity, A. said lower member being characterized by: a. at least one downwardly concave bottom surface that forms the lower portion of said at least one cavity, b. a substantially vertical annular inner sidewall extending upwardly from the periphery of each said concave bottom surface, c. a bottom shelf portion extending substantially horizontally outwardly from said inner sidewall, d. an outer sidewall portion extending substantially vertically downwardly from the outer periphery of said bottom shelf portion, e. said bottom shelf portion and said outer sidewall defining an annular channel around the periphery of each concave bottom surface, B. said upper member being characterized by a. at least one upwardly convex surface that forms the upper portion of said at least one cavity, b. a first cover sidewall portion extending vertically upwardly from the periphery of each said convex surface, c. a first cover shelf portion extending substantially horizontally outwardly from said first cover sidewall portion, d. the first cover sidewall portion and said first cover shelf portion being snugly interengageable with the outer surface of the corner formed by the said inner sidewall and the said bottom shelf portion of said lower member, e. a second cover sidewall portion extending vertically upwardly from the periphery of saiD first cover shelf portion, f. a second cover shelf portion extending substantially horizontally outwardly from said second cover sidewall portion, g. the aforesaid second cover sidewall portion and said second cover shelf portion having an outer surface configuration that is slightly smaller than the interior configuration of the corner formed by said inner sidewall and said bottom shelf portion of said lower member.
 2. A packing unit according to claim 1 wherein said concave bottom surface is provided with a radial groove which is adapted to receive a pincette to facilitate the removal of the material resting on said surface.
 3. A packing unit according to claim 1 wherein said packing unit is composed of a synthetic resin having a thickness between about 0.1 mm and about 1.0 mm.
 4. A packing unit for items such as thin semiconductor wafers which comprises cooperating lower and upper members that are adapted to fit together so as to form a plurality of cavities: A. said lower member being characterized by: a. a plurality of spaced apart downwardly concave bottom surfaces that define the bottom portions of the aforesaid plurality of cavities, b. a substantially vertical annular inner sidewall extending upwardly from the periphery of each of said concave bottom surfaces, c. a bottom shelf portion extending substantially horizontally outwardly from the inner sidewall of each of said concave bottom surfaces, d. outer sidewall portions extending substantially vertically downwardly from the outer periphery of each of said bottom shelf portions, e. each of said bottom shelf portions of each of said outer sidewall portions defining an annular channel around the periphery of each concave bottom surface, B. said upper member being characterized by: a. a plurality of spaced apart upwardly convex surfaces that form the cover portions of said plurality of cavities, b. a first cover sidewall portion extending vertically upwardly from the periphery of each said convex surface, c. a first cover shelf portion extending substantially horizontally outwardly from each said first cover sidewall portion, d. the under surface of the first cover sidewall portion and the first cover shelf portion of each convex surface being snugly interengageable with the outer surface of the corner defined by the intersection of said inner sidewall and said bottom shelf portion of each corresponding concave surface in the lower member, e. a second cover sidewall portion extending vertically upwardly from the periphery of each of said first cover shelf portions, f. a second cover shelf portion extending substantially horizontally outwardly from each second cover sidewall portion, g. each of the aforesaid second cover sidewall portions and second cover shelf portions having an outer surface configuration that is slightly smaller than the interior surface configuration of the corner formed by the intersection of said inner sidewall portion and the bottom shelf portion of said lower member.
 5. A packing unit according to claim 4 wherein said concave bottom surface is provided with a radial groove which is adapted to receive a pincette to facilitate the removal of the material resting on said surface.
 6. A packing unit according to claim 4 wherein said packing unit is composed of a synthetic resin having a thickness between about 0.1 mm and about 1.0 mm.
 7. A container unit for thin sheet materials such as semiconductor wafers which comprises cooperating lower and upper members that are adapted to fit together so as to form a plurality of cavities wherein: A. said lower member is characterized by a. a plurality of spaced apart downwardly concave bottom surfaces, b. a first annular channel section of a generally U-shaped configuration disposed around the periphery of each concave bottom surface, B. said upper member is characterized by a. a plurality of spaCed apart upwardly convex cover surfaces, b. a second annular channel section disposed around the periphery of each convex cover surface which can be considered as consisting of a stepped U-shaped configuration that includes a receptor portion and a projector portion that is smaller than said receptor portion, C. said concave bottom surfaces and said convex cover surfaces being vertically aligned with each other when said lower and upper members are functioning as a container, D. the exterior surface of said first annular channel section having a size and configuration that is adapted to fit within the interior surface of the receptor portion of said second annular channel section in a nesting relationship. E. the interior surface of said first annular channel section having a size and configuration that is adapted to accommodate the exterior surface of the projector portion of said second annular channel section in a nesting relationship.
 8. A container according to claim 7 wherein said concave bottom surface is provided with a radial groove which is adapted to receive a pincette to facilitate the removal of the material resting on said surface.
 9. A container according to claim 7 wherein said packing unit is composed of a synthetic resin having a thickness between about 0.1 mm and about 1.0 mm. 